Esters of drastically oxidized dehydrated castor oil fatty acids with oxyalkylated phenol aldehyde resins



Patented Jan. 8, 1952 ESTERS OF DRASTICALLY OXIDIZEDDEHY DRATED CASTOR OIL FATTY ACIDS WITH OXYALKYLATED PHENOL ALDEHYDE r 7 RE S-IN S Melvin De Groote, St. Louis, and- Bernhard" Keiser, Webster Groves, Mo., assigrrorsto Petro lite Corporation, Ltd., Wilmington, Del., a corporation of Delaware 1 N Drawing. Application December 10, 1948,

Serial No. 64,459 g The present invention is concerned with certain new chemical products, compounds or compositions, having useful applications in various arts. This invention is a continuation-in-part of our rec-pending application, Serial No. 726,214, filed February 3, 1947, and now abandoned. It includes methods or procedures for manufacturing said new products, compounds or compositions, as well as the products, compounds or compositions themselves. Said new compositions are esters in which the acyl radical is that of the fatty acid of drastically-oxidized dehydrated castor oil, and the alcoholic radical is that of certain hydrophile polyhydric synthetic products; saidhydrophile synthetic products being oxalkylation products of (A) an alpha-beta alkylene oxide having not more than 4 carbon atoms and selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide and methylglycide, and (B) an oxyalkylation-susceptible, fusible, organic solvent-soluble, water- Y insoluble phenol-aldehyde resin; said resin being derived by reaction between a difunctional monohydric phenol and an aldehyde having not over 8 carbon atoms and reactive toward said phenol; said resin being formed in the substantial absence of trifunctional phenols; said phenol being of. the formula in which R is a hydrocarbon radical having at least 4 and not more than 12 carbon atoms and substituted in the 2,4,6 position, said oxyalkylated 7 Claims. (o1. 260-19) number ,of industrial applications, they are of particular value for resolving petroleum emul sions of the water-in-oil type that are commonly referred to as cut oil, roily oil, emulsified,

oil, etc'., and which comprise fine droplets of naturally-occurring waters or brines dispersed a more or less permanent state throughout the oil which constitutes the continuous phase of the emulsion. This specific application is describedand claimed in our co-pending application, Serial No. 64,460, filed December 10, 1948, now Patent No. 2,541,997,. issued February 20, 1951. See-also our col-pending. application, Serial No. 64,469, filed December-10, 1948. I The new products are useful as wetting, detergent and levelling agents the laundry, textile and dyeing industries; as Wetting agents and detergents in the acid washing of building stone and brick as" wetting agents and spreadersin the application of asphalt in road buildingfand the like; as a flotation reagent in the flotation separation of various. aqueous suspensions con-' taining negatively charged particles such as sewage, coal washing wa'stewater, and varioustrade wastes and the like; as germici'des, insecticides, emulsifying agents, as for example, for cosmetics,- spray oils, water-repellent textile finishes; as lu-- bricants, etc. e

For'purp'ose of conveniencewhat issaid hereinafter will be divided into three parts. Part I will be concerned withthe production of the-resin from a difunctional phenol and an aldehyde; Part 2' will be concerned with the oxyall'zylation of the resin seas-to convert it into a hydrophile hydroxylated' derivative; and Part 3 will beconcerned with the conversion of the immediately aforementioned derivative into a total or partial ester by reaction with anacid, an ester, or other functional derivative, so as to; obtain a compound ofthe kind previously specified and subsequently described in detail.

, PART 1 As to the prepartion of the phenol-aldehyde resins reference is made to'ou'r co-pending ap? plications, Serial Nos. 8,736 and 8,731 both filed February 1 6 1948', both of which are now abandomed. In such ctr-pending applications we defscribed a fusible, organic solvent-soluble, waterinsoluble resin polymer of the formula In such idealized representation 11." is a numeral varying from 1 to 13 or even more, provided that the resin is fusible and organic solvent-soluble. R is a hydrocarbon radical having at least 4 and not over 8 carbon atoms. In the instant application B may have as many as 12 carbon atoms, as in the case of a resin obtained from a dodecylphenol. In the instant invention it may be first suitable to describe the alkylene oxides employed as reactants, then the aldehydes, and finally the phenols, for the reason that the latter require a more elaborate description.

The alkylene oxides which may be used are the alpha-beta oxides having not more than 4 carbon atoms, to wit, the alpha-beta ethylene oxide, alpha-beta propylene oxide, alpha-beta butylene oxide, glycide, and methylglycide.

Any aldehyde capable of forming a methylol or a substituted methylol group and having not more than 8 carbon atoms is satisfactory, so long as it does not possess some other functional group or structure which will conflict with the resinification reaction or with the subsequent oxyalkylation of the resin, but the use of formaldehyde, in its cheapest form of an aqueous solution, for the production of the resins is particularly advantageous. Solid polymers of formaldehyde are more expensive and higher aldehydes are both less reactive, and are more expensive Furthermore, the higher aldehydes may undergo other reactions which are not desirable, thus introducing difficulties into the resinification step. Thus acetaldehyde, for example, may undergo an aldol condensation, and it and most of the higher aldehydes enter into self-resiniflcation when treated with strong acids or alkalies. On the other hand, higher aldehydes frequently beneficially affect the solubility and fusibility of a resin. This is illustrated, for example, by the different characteristics of the resin prepared from para-tertiary amylphenol and formaldehyde on one hand, and a comparable product prepared from the. same phenolic reactant and heptaldehyde on the other hand. The former, as shown in certain subsequent examples, is a hard, brittle, solid, whereas the latter is soft and tacky, and obviously easier to handle in the subsequent oxyalkylation procedure.

Cyclic aldehydes may be employed, particularly benzaldehyde. The employment of furfural requires careful control for the reason that in addition to its aldehydic function, furfural can form condensations by virtue of its unsaturated structure. The production of resins from furfural for use in preparing products from the present process is most conveniently conducted with weak alkaline catalysts and often with alkali metal carbonates. Useful aldehydes, in addition to formaldehyde, are acetaldehyde, propionic aldehyde, butyraldehyde, 2 ethylhexanal, ethylbutyraldehyde, heptaldehyde, and benzaldehyde, furfural and glyoxal. It would appear that the use of glyoxal should be avoided due to the fact that it is tetrafunctional. However, our experience has been that, in resin manufacture and particularly as described herein, apparently only one of the aldehydic functions enters into the 4 resinification reaction. The inability of the other aldehydic function to enter into the reaction is presumably due to steric hindrance. Needless to say, one can use a mixture of two or more aldehydes although usually this has no advantage.

Resins of the kind which are used as intermediates in this invention are obtained with the use of acid catalysts or alkaline catalysts, or without the use of any catalyst at all. Among the useful alkaline catalysts are ammonia, amines, and quaternary ammonium bases. It is generally accepted that when ammonia and amines are employed as catalysts they enter into the condensation reaction and, in fact, may operate by initial combination with the aldehydic reactant. The compound hexamethylenetetramine illustrates such a combination. In light of these various reactions it becomes difiicult to present any formula which would depict the structure of the various resins prior to oxyalkylation. More will be said subsequently as to the difference between the use of an alkaline catalyst and an acid catalyst; even in the use of an alkaline catalyst there is considerable evidence to indicate that the products are not identical where different basic materials are employed. The basic materials employed include not only those previously enumerated but also the hydroxides of the alkali metals, hydroxides of the alkaline earth metals, salts of strong bases and weak acids such as sodium acetate, etc.

suitable phenolic reactants include the following: Para-tertiarybutylphenol; para-secondarybutylphenol; para-tertiary-amylphenol; parasecondary-amylphenol; paratertiary-hexylphenol; para-isooctylphenol: ortho-phenylphenol; para-phenylphenol; ortho-benzylphenol; parabenzylphenol; and para-cyclohexylphenol, and the corresponding ortho-para substituted metacresols and 3,5-xylenols. Similarly, one may use paraor ortho-nonylphenol or a mixture, paraor decylphenol or a mixture, menthylphenol, or paraor ortho-dodecylphenol. v

The phenols herein contemplated for reaction may be indicated by the following formula:

in which R is selected from the class consisting of hydrogen atoms and hydrocarbon radicals having at least 4 carbon atoms and not more than 12 carbon atoms, with the proviso that one occurrence of R is the hydrocarbon substitutent and the other two occurrences are hydrogen atoms, and with the further provision that one or both of the 3 and 5 positions may be methyl substituted.

The above formula possibly can be restated more conveniently in the following manner, to wit, that the phenol employed is of the following formula, with the proviso that R is a hydrocarbon substituent located in the 2,4,6 position, again with the provision as to 3 or 3,5 methyl substitution. This is conventional nomenclature, numbering the various positions in the usual clockwise manner, beginning with the hydroxyl position as one:

Themanufacture of thermoplastic phenol-.alde-l hyde .resins, particularly from formaldehyde and a difunctional phenol, i. e., a phenol in which one of the three reactive positions (2,4,6) has been substituted by a hydrocarbon group, and particularly by one having at least 4 carbon atoms and not more than 12 carbon atoms, is well known. As has been previously pointed out, there is no objection to a methyl radical provided it is present in the 3 or position.

These resins, used as intermediates to produce the products of the present invention are'described in detail in our Patent 2,499,370, granted March '7, 1950, and specific examples of suitable resins are those of Examples 1a through 1030. of that patent, and reference is made thereto for a description of these intermediate resins and for examples thereof.

PART 2 Having obtained a suitable resin 'of the kind described, such resin is subjected to treatment with a low molal reactive alpha-beta olefin oxide so as to render the product distinctly hydrophile in nature as indicated by the fact that it becomes self-emulsifiable or miscible or soluble in water, or self-dispersible, or has emulsifying properties. The olefin oxides employed are characterized by the fact that they contain not over 4 carbon atoms and are selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide, and methylglycide. Glycide may be, of course, considered as a hydroxy propylene oxide and methyl glycide as a hydroxy butylene oxide. In any event, however, all such reactants contain the reactive ethylene oxide ring and may be best considered as derivatives of or substituted ethylene oxides. The solubilizing effect of the oxide is directly proportional to the percentage of oxygen present, or specific-ally, to the oxygen-carbon ratio.

In ethylene oxide, the oxygen-carbon ratio is 1:2. In glycide, it is 2:3; and in methyl glycide, 1:2. In such compounds, the ratio is very favorable to the production of hydrophile Or surfaceactive properties. Howeventha ratio, in propylene oxide, is 1:3, and in butylene oxide, 1:4. 'Obviously, such latter two reactants are satisfactorily employed only where the resin composition is such as to make incorporation of the. desired property practical. In other cases, they may produce marginally satisfactory derivatives, or even unsatisfactory derivatives. They are usable in conjunction with the three more favorable alkylene oxides in all cases. For instance, after one or several propylene oxide or butylene oxide mole cules have been attached to the resin molecule, oxyalkylation may be satisfactorily continued using the more favorable members of the class, to produce the desired hydrophile product. Used alone, these two reagents may in some cases fail to produce sufficiently hydrophile derivatives because of their relatively low oxygen-carbon ratios.

Thus, ethylene oxide is much more effective than propylene oxide, and propylene oxide is more effective than butylene oxide. Hydroxy propylene oxide (glycide) is more efiective than propylene oxide. Similarly, hydroxy butylene oxide (methyl glycide) is more effective than butylene oxide. Since ethylene oxide is the cheapest alkylene oxide available and is reactive, its use is definitely advantageous, and especially in light of its high oxygen content. Propylene oxide is less reactive than ethylene oxide, and

butylene oxide is definitely less reactive than propylene oxide. On the other hand, glycide, may react with almost explosive violence and must be handled with extreme care.

The oxyalkylation of resins of the kind from which the initial reactants used in the practice of the present invention are prepared is advantageously catalyzed by the presence of an alkali. Useful alkaline catalysts include soaps, sodium acetate, sodium hydroxide, sodium methylate, caustic potash, etc. The amount of alkaline catalyst usually is between 0.2% to 2%. The temperature employed may vary from room temperature to as high as 200 C. The reaction may be conducted with or without pressure, i. e., from zero pressure to approximately 200 or even 300 pounds gauge pressure (pounds per square inch). In a general way, the method employed is substantially the same procedure as used for oxyalkylation of other organic materials having reactive phenolic groups.

It may be necessary to allow for the acidity of a resin in determining the amount of alkaline catalyst to be added in oxyalkylation. For instance, if a nonvolatile strong acid such as sulfuric acid is used to catalyze the resinification reaction, presumably after being converted into a sulfonic acid, it may be necessary and is usually advantageous to add an amount of alkali equal stoichiometrically to such acidity, and include added alkali over and'above this amount as the alkaline catalyst.

It is advantageous to conduct the oxyethylation in presence of an inert solvent such as xylene, cymene, decalin, ethylene glycol diethylether, diethyleneglycol diethylether, or the like, although with many resins, the oxyalkylation proceeds satisfactorily without a solvent. Since xylene is cheap and may be permitted to be present in the final product used as 'ademulsifier, it is our preference to use xylene. This is particularly true in the manufacture of products from lowstage resins, i. e., of 3 and up to and including 7 units per molecule.

If a xylene solution is used in an autoclave as hereinafter indicated, the pressure readings of course represent total presure, that is, the combined pressure due to xylene and also due to ethylene oxide or whatever other oxyalkylating agent is used. Under such circumstances it may be necessary at times to use substantial pressures to obtain effective results, for instance, pressures up to 300 pounds along with correspondingly high temperatures, if required.

However, even in the instance of high-melt ing resins, a solvent such as xylene can be eliminated in either one of two ways: After the introduction of approximately 2 or 3 moles of ethylene oxide,'for example, per phenolic nucleus, there is a definite drop in the hardness and melting point of the resin. At this stage, if xylene or a similar solvent has been added, it can be eliminated by distillation (vacuum distillation if desired) and the subsequent intermediate, being comparatively soft and solvent-free, can be reacted further in the usual manner with ethylene oxide or some other suitable reactant.

Another procedure is to continue the reaction to completion with such solvent present and then eliminate the solvent by distillation in the customary manner.

Another suitable procedure is to use propylene oxide or butylene oxide as a solvent as well as a ieactan't in the earlier stages along with ethylene oxide, for instance, by dissolving the powdered resin in propylene oxide even though oxyalkylation is taking place to a greater or lesser degree. After a solution has ben obtained which represents the original resin dissolved in propylene oxide or butylene oxide, or a mixture which includes the oxyalkylated product, ethylene oxide is added to react with the liquid mass until hydrophile properties are obtained. Since ethylene oxide is more reactive than propylene oxide or butylene oxide, the final product may contain some unreacted propylene oxide or butylene oxide which can be eliminated by volatilization or distillation in any suitable manner.

Attention is directed to the fact that the resins herein described must be fusible or soluble in an organic solvent. Fusible resins invariably are soluble in one or more organic solvents such as those mentioned elsewhere herein. It is to be emphasized, however, that the organic solvent employed to indicate or assure that the resin meets this requirement need not be the one used in oxyalkylation. Indeed, solvents which are susceptible to oxyalkylation are included in this group of organic solvents. Examples of such solvents are alcohols and alcohol-others. How ever, where a resin is soluble in an organic solvent, there are usually available other organic solvents which are not susceptible to oxyalkylation, useful for the oxyalkylation step. In any event, the organic solvent-soluble resin can be finely powdered, for instance to 100 to 200 mesh, and a slurry or suspension prepared in xylene or the like, and subjected to oxyalkylation. The fact that the resin is soluble in an organic solvent or the fact that it is fusible means that it consists of separate molecules. Phenol-aldehyde resins of the type herein specified possess reactive hydroxyl groups and are oxyalkylation susceptible.

Considerable of what is said immediately hereinafter is concerned with ability to vary the hydrophile properties of the hydroxylated intermediate reactants from minimum hydrophile properties to maximum hydrophile properties. Such properties in turn, of course, are effected subsequently by the acid employed for esterification and the quantitative nature of the esterification itself, i. e., whether it is total or partial. It may be well, however, to point out what has been said elsewhere in regard to the hydroxylated intermediate reactants. See, for example, our co-pending applications, Serial Nos. 8,730 and 8,731, both filed February 16, 1948, and Serial No. 42,133, filed August 2, 1948, and Serial No. 42,134, filed August 2, 1948, all four of which are now abandoned. The reason is that the esterification, depending on the acid selected, may vary the hydrophile-hydrophobe balance in one direction or the other, and also invariably causes the development of some property which makes it inherently different from the two reactants from which the derivative ester is obtained.

Referring to the hydrophile hydroxylated intermediates, even more remarkable and equally difficult to explain, are the versatility and the utility of these compounds considered as chemical reactants as one goes from minimum hydrophile property to ultimate maximum hydrophile property. For instance, minimum hydrophile property may be described roughly as the point where two ethyleneoxy radicals or moderately in excess thereof are introduced per phenolic hydroxyl.

Such minimum hydrophile property or sub-surface-activity or minimum surface-activity means that the product shows at least emulsifying properties or self-dispersion in cold or even in warm distilled water (15 to 40 C.) in concentrations of 0.5% to 5.0%. These materials are generally more soluble in cold water than warm water, and may even be very insoluble in boiling water. Moderately high temperatures aid in reducing the viscosity of the solute under examination. Sometimes if one continues to shake a hot solution, even though cloudy or containing an insoluble phase, one finds that solution takes place to give a homogeneous phase as the mixture cools. Such self-dispersion tests are conducted in the absence of an insoluble solvent.

When the hydrophile-hydrophobe balance is above the indicated minimum (2 moles of ethylene oxide per phenolic nucleus or the equivalent) but insufficient to give a sol as described immediately preceding, then, and in that event hydrophile properties are indicated by the fact that one can produce an emulsion by having present 10% to 50% of an inert solvent such as xylene. All that one need to do is to have a xylene solution within the range of 50 to parts by weight of oxyalkylated derivatives and 50 to 10 parts by weight of xylene and mix such solution with one, two or three times its volume of distilled water and shake vigorously so as to obtain an emulsion which may be of the oil-in-Water type or the water-in-oil type (usually the former) but, in any event, is due to the hydrophile-hydrophobe balance of the oxyalkylated derivative. We prefer simply to use the xylene diluted derivatives, which are described elsewhere, for this test rather than evaporate the solvent and employ any more elaborate tests, if the solubility is not sufiicient to permit the simple sol test in water previously noted.

If the product is not readily Water soluble it may be dissolved in ethyl or methyl alcohol, ethylene glycol diethylether, or diethylene glycol diethylether, with a little acetone added if required, making a rather concentrated solution, for instance 40% to 50%, and then adding enough of the concentrated alcoholic or equivalent solution to give the previously suggested 0.5% to 5.0% strength solution. If the product is self-dispersing (i. e., if the oxyalkylated product is a liquid or a liquid solution self-emulsifiable) such sol or dispersion is referred to as at least semi-stable in the sense that sols, emulsions, or dispersions prepared are relatively stable, if they remain at least for some period of time, for instance 30 minutes to two hours, before showing any marked separation. Such tests are conducted at room temperature (22 C.) Needless to say, a test can be made in presence of an insoluble solvent such as 5% to 15% of xylene, as noted in previous examples. If such mixture, i. e., containing a waterinsoluble solvent, is at least semi-stable, obviously the solvent-free product would be even more Surface-activity representing an advanced hydrophile-hydrophobe balance can also be determined by the use or conventional measurements hereinafter described. One outstanding characteristic property indicating surface-activity in a material is the ability to form a permanent foam in dilute aqueous solution, for example, less than 0.5%, when in the higher oxyalkylated stage, and to form an emulsion in the lower and intermediate stages of oxyalkylation.

Allowance must be made for the presence of a solvent in the final product in relation to the hydrophile properties of the final product. The principle involved in the manufacture of the herein contemplated compounds for use as polyhydric reactants, is based on the conversion of a hydrophobe or non-hydrophile compound or mixture of compounds into products which are distinctly hydrophile, at least to the extent that they have emulsifying properties or are selfemulsifying; that is, when shaken with water they produce stable or semi-stable suspensions, or, in the presence of a water-insoluble solvent, such as xylene, an emulsion. In demulsification, it is sometimes preferable to use a product having markedly enhanced hydrophile properties over and above the initial stage of self-emulsifiability, although we have found that with products of the type used herein, most efficacious results are obtained with products which do not have hydrophile properties beyond the stage of self-dispersibility.

More highly oxyalkylated resins give colloidal solutions or sols which show typical properties comparable to ordinary surface-active agents. Such conventional surface-activity may be measured by determining the surface tension and the interfacial tension against paraflin oil or the like. At the initial and lower stages of oxyalkylation, surface-activity is not suitably determined in this same manner but one may employ an emulsification test. Emulsions come into existence as a rule through the presence of a surface-active emulsifying agent. Some surface-active emulsifying agents such as mahogany soap may produce a water-in-oil emulsion or an oil-in-water emulsion depending upon the ratio of the two phases, degree of agitation, concentration of emulsifying agent, etc.

The same is true in regard to the oxyalkylated resins herein specified, particularly in the lower stage of oxyalkylation, the so-called sub-surfaceactive stage. The surface-active properties are readily demonstrated by producing a xylenewater emulsion. A suitable procedure is as follows: The oxyalkylated resin is dissolved in an equal weight of xylene. Such 50-50 solution is then mixed with 1-3 volumes of water and shaken to produce an emulsion. The amount of xylene is invariably sufficient to reduce even a tacky resinous product to a solution which is readily dispersible. The emulsions so produced are usually xylene-in-water emulsions (oil-in-water type) particularly when the amount of distilled water used is at least slightly in excess of the volume of xylene solution and also if shaken vigorously. At times, particularly in the lowest stage of oxyalkylation, one may obtain a water-inxylene emulsion (water-in-oil type) which is apt to reverse on more vigorous shaking and further dilution with water.

If in doubt as to this property, comparison with aresin obtained from para-tertiary butylphenol and formaldehyde (ratio 1 part phenol to 1.1 formaldehyde) using an acid cataylst and then followed by oxyalkylation using 2 moles of ethylene oxide for each phenolic hydroxyl, is helpful. Such resin prior to cxyalkylation has a molecular weight indicating about i units per resin molecule. Such resin, when diluted with an equal weight of xylene, will serve to illustrate the above emulsification test.

In a few instances, the resin may not be sufiiciently soluble in. xylene alone but may require the addition of some ethylene glycol diethylether as described elsewhere.

It is und rsto d tha such mixture, or any other similar mixture, is considered the equivalent of xylene for the purpose of this test.

In many cases, there is no doubt as to the presence or absence of hydrophile or surface-active characteristics in the polyhydric reactants used in accordance with this invention. They dissolve or disperse in water; and such dispersions foam readily. With borderline cases, i. e., those-which show only incipient hydrophile or surface-active property (sub-surface-activity) testslfor emulsifying properties or self-dispersibility are useful. The fact that a reagent is capable of producing a dispersion in water is proof that it is distinctly hydrophile. In doubtful cases, comparison can be made with the butylphenol-formaldehyde resin analog wherein 2 moles of ethylene oxide have been introduced for each phenolic nucleus.

The presence of xylene or an equivalent waterinsoluble solvent may mask the point at which a solvent-free product on mere dilution in. a test tubeexhibits self-emulsification. For this reason, if it is desirable to determine the approximate point where self-emulsification begins, then it is better to eliminate the xylene or equivalent from a small portion of the reaction mixture and test such portion. In some cases, such xylene-free resultant may show initial or incipient hydrophile properties, whereas in presence of xylene such properties would not be noted. In other cases, the first objective indication of hydrophile properties may be the capacity of the material to emulsify an insoluble solvent such. as xylene. It is to be emphasized that hydrophile properties herein referred to are such as those exhibited by incipient self-emulsification or. the presence of emulsifying proprties and go through the range of homogeneous dispersibility or admixture with water even in presence ofadded water-insoluble solvent and minor proportions of common electrolytes as occur in oil field brines.

Elsewhere, it ispointed out thatan emulsification test may be used to determine ranges of surface-activity and that such emulsification tests employ a xylene solution. Stated another way, it is really immaterial whether a xylene solution produces a sol or whether it merely produces. an emulsion.

In light of what has beensaid previously in regard to the variation of range of hydrophile properties, and also in light of. what has been said as to the variation. the effectiveness of various alkylene oxides, and most particularly of all ethylene oxide, to introduce hydrophile character, it becomes obvious that there is a wide variation in the amount of alkylene oxide employed, as long as it is at least 2 moles per phenolic nucleus, for producing products useful for the practice of this invention. Another variation is the molecular size of the resin chain resulting from reaction between the difunctional phenol and the aldehyde. such as formaldehyde. It is well known that the size and nature or structure of the resin polymer obtained varies some.- what with the conditions of reaction, the proportions of reactants, the nature of the catalyst, etc.

Based on molecular weight determinations, most of the resins prepared as herein described, particularly in theabsenceof a secondary heating step, contain 3 to 6 or '7 phenolic nuclei with approximately 4 or 5 nuclei as an average. More drastic conditions of resinification yield resins of greater chain length. Such more intensive resinification is a conventional procedure and may be employed if desired. Molecuwithout the use of vacuum.

We have previously pointed out that either an alkaline or acid catalyst is advantageously used in preparing the resin. A combination of catalysts is sometimes used in two stages; for instance, an alkaline catalyst is sometimes employed in a first stage, followed by neutralization and addition of a small amount of acid catalyst in a second stage. It is generally believed that even in the presence of an alkaline catalyst, the number of moles of aldehyde, such as formaldehyde, must be greater than the moles of phenol employed in order to introduce methylol groups in the intermediate stage. There is no indication that such groups appear in the final resin if prepared by the use of an acid catalyst. It is possible that such groups may appear in the finished resins prepared solely with an alkaline catalyst; but we have never been able to confirm this fact in an examination of a large number of resins prepared by ourselves. Our preference, however, is to use an acid-catalyzed resin, particularly employing a formaldehyde-to-phenol ratio of 0.95 to 1.20 and, as far as we have been able to determine, such resins are free from methylol groups. As a matter of fact, it is probable that in acidcatalyzed resinifications, the methylol structure may appear only momentarily at the'very beginning of the reaction and in all probability is converted at once into a more complex structure during the intermediate stage.

One procedure which can be employed in the use of a new resin to prepare polyhydric reactants for use in the preparation of compounds employed in the present invention, is to determine the hydroxyl value by the Verley-Bdlsing method or its equivalent. The resin as such, or in the form of a solution as described, is then treated with ethylene oxide in presence of 0.5%

to 2% of sodium methylate as a catalyst in stepwise fashion. The conditions of reaction, as far as time or per cent are concerned, are within the range previously indicated. With suitable agitation the ethylene oxide, if added in molecular proportion, combines within a comparatively short time, for instance a few minutes to 2 to 6 hours, but in some instances requires as much as 8 to 24 hours. A useful temperature range is from 125 to 225 C. The completion of the reaction of each addition of ethylene oxide in stepwise fashion is usually indicated by the reduction or elimination of pressure. An amount conveniently used for each addition is generally equivalent to a mole or two moles of ethylene oxide per hydroxyl radical. When the amount of ethylene oxide added is equivalent to approximately 50% by weight of the original resin, a sample is tested for incipient hydrophile properties by simply shaking up in water as is, or after the elimination of the solvent if a solvent is present. The amount of ethylene oxide used to obtain a useful demulsifying agent as a rule varies from 70% by weight of the original resin to as much as five or six times the weight of the original resin. In the case of a resin derived from para-tertiary butylphenol, as little as 50% by weight of ethylene oxide may give suitable solubility. With propylene oxide, even a greater molecular proportion is required and sometimes a resultant of only limited hydrophile properties is obtainable. The same is true to even a greater extent with butylene oxide. The hydroxylated alkylene oxides are more effective in solubilizing properties than the comparable compounds in which no hydroxyl is present.

Attention is directed to the fact that in the subsequent examples reference is made to the step-Wise addition of the alkylene oxide, such as ethylene oxide. It is understood, of course. there is no objection to the continuous addition of alkylene oxide until the desired stage of reaction is reached. In fact, there may be less of a hazard involved and it is often advantageous to add the alkylene oxide slowly in a continuous stream and in such amount as to avoid exceeding the higher pressures noted in the various examples or elsewhere.

It may be well to emphasize the fact that when resins are produced from difunctional phenols and some of the higher aliphatic aldehydes, such as acetaldehyde, the resultant is a comparatively soft or pitch-like resin at ordinary temperatures. Such resins become comparatively fluid at to C. as a rule, and thus can be readily oxyalkylated, preferably oxyethylated, without the use of a solvent.

What has been said previously is not intended to suggest that any experimentation is necessary to determine the degree of oxyalkylation, and particularly oxyethylation. What has been said previously is submitted primarily to emphasize the fact that these remarkable oxyalkylated resins having surface activity show unusual properties as the hydrophile character 'varies from a minimum to an ultimate maximum. One should not underestimate the utility of any of these polyhydric alcohols in a surface-active or sub-surface-active range without examining them by reaction with a number of the typical esters herein described and subsequently examinin the resultant for utility, either in demulsification or in some other art or industry as referred to elsewhere, or as a reactant for the manufacture of more complicated derivatives. A few simple laboratory tests which can be conducted in a routine manner will usually give all the information that is required.

For instance, a simple rule to follow is to prepare a resin having at least three phenolic nuclei and being organic solvent-soluble. Oxyethylate such resin, using the following four ratios of moles of ethylene oxide per phenolic unit equivalent: 2 to 1; 6 to 1; 10 to l; and 15 to 1. From a sample of each product remove any solvent that may be present, such as xylene. Prepare 0.5% and 5.0% solutions in distilled water, as previously indicated. A mere examination of such series will generally reveal an approximate range of minimum hydrophile character, moderate hydrophile character, and maximum hydrophile character. If the 2 to 1 ratio does not show minimum hydrophile character by test of the solvent-free product, then one should test its capacity to form an emulsion when admixed with xylene or other insoluble solvent. If neither test shows the required minimum hydrophile property, repetition using 2% to l moles per phenolic nucleus will serve. Moderate hydrophile character should be shown by either the 6 to 1 or 10 to 1 ratio. Such moderate hydro- 13 phile character is indicated by the fact that the sol in distilled water within the previously mentioned concentration range is a permanent translucent sol when viewed in a comparatively thin layer, for instance the depth of a test tube. Ultimate hydrophile character is usually shown at the 15 to 1 ratio test in that adding a small amount of an insoluble solvent, for instance 5% of xylene, yields a product which will give, at least temporarily, a transparent or translucent sol of the kind just described. The formation of a permanent foam, when a 0.5% to 5.0% aqueous solution is shaken, is an excellent test for surface activity. Previous reference has been made to the fact that other oxyalkylating agents may re quire theuse of increased amounts of alkylene weight, and a third example using about 500% to 750% by weight, to explore the range of hydrophile-hydrophobe balance.

A practical examination of the factor of oxyalkylation level can be made by a very simple test using a pilot plant autoclave having a ca- 0 pacity of about to gallons as hereinafter described. Such laboratory-prepared routine compounds can then be tested for solubility and, generally speaking, this is all that is required to ive a suitable variety covering the hydrophilehydrophobe range. All these tests, as stated, are

intended to be routine tests and nothing more.

They are intended to teach a person, even though unskilled in oxyethylation or oxyalkylation, how to prep-are in a perfectly arbitrary manner, a series of compounds illustrating the hydro-philohydrophobe range.

If one purchases a thermoplastic or fusible resin on the open market selected from a suitable number which are available, one might have to make certain determinations in order to make the quickest approach to the appropriate oxyalkylation range. For instance, one should know '(a) the molecular size, indicating the number of phenolic units; b) the nature of the aldehydic residue, which is usually CH2; and (c) the nature of the substituent, which is usually butyl, amyl, or phenyl. With such information one is in substantially the same position as if one had personally made the resin prior to oxyethylation.

For instance, the molecular weight of the internal structural units of the resin of the following over-simplified formula:

on on OH e F rel R R R (n=i to 13, or even more) is given approximately by the formula: (mol. wt. of phenol 2) plus mol. wt. of methylene or substituted methylene radical. The molecular weight of the resin would be n times the value for the internal limit plus the values for the terminal units. The left-hand terminal unit of the above structural formula, it will be seen, is identical with the recurring internal unit except that it has one extra hydrogen. The right-hand terminal unit lacks the methylene bridge element.

Using one internal unit of a resin as the basic element, a resins molecular weight is given approximately by taking (n plus 2), times the weight of the internal element. Where the resin molecule has only 3 phenolic nuclei as in the structure shown, this calculation will be in error by several per cent; but as it grows larger, to contain 6, 9, or 12 phenolic nuclei, the formula comes to be more than satisfactory. Using such an approximate weight, one need only introduce, for example, two molal Weights of ethylene oxide or slightly more, per phenolic nucleus, to produce a product of minimal hydrophile character. Further oxyalkylation gives enhanced hydrophile character. Although we have prepared and tested a large number of oxyethylated products of the type described herein, we have found no instance where the use of less than 2 moles of ethylene oxide per phenolic nucleus gave desirable products.

Examples 11) through 18b and the tables which appear in columns 51 through 56 of our said Patent 2,499,370 illustrate oxyalkylation products from resins which are useful as intermediates for producing the esterified products of the present invention, such examples giving exact and complete details for carrying out the oxyalkylation procedure.

The resins, prior to oxyalkylation, vary from tacky, viscous liquids to hard, high-melting solids. Their color varies from a light yellow through amber, to a deep red or even almost black. In the manufacture of resins, particularly hard. resins, as the reaction progresses the reaction mass frequently goes through a liquid state to a subresinous or semi-resinous state, often characterized by being tacky or sticky, to a final complete resin. As the resin is subjected to oxyalkylation these same physical changes tend to take place in reverse. If one starts with a solid resin, oxyalkylation tends to make it tacky or semi-resinous and further oxyalkylation makes the tackiness disappear and changes the product to a liquid.

Thus, as the resin is oxyalkylated it decreases in viscosity, that is, becomes more liquid or changes from. a solid to aliquid, particularly when it is converted to the water-dispersible or water-soluble stage. The color of the oxyalkylated derivative is usually considerably lighter than the original product from which it is made, varying from a pale straw color to an amber or reddish amber. The viscosity usually varies from that of an oil, like castor oil, to that of a thick viscous sirup. Some products are waxy. The presence of a solvent, such as 15% xylene or the like, thins the viscosity considerably and also reduces the color in dilution. No undue significance need be attached to the color for the reason that if the same compoundv is prepared in glass and in iron, the latter usually has somewhat darker color. If the resins are prepared'as customarily employed in varnish resin manufacture, i. e., a procedure that excludes the presence of oxygen during the resinific'ation and. subsequent cooling of the resin, then of course the initial resin is much lighter in color. We have employed some resins which initially are almost water-white and also yield a lighter colored final product.

Actually, in considering the ratio of alkylene oxide to add, and we have previously pointed out that this can be pre-determined using laboratory tests, it is our actual preferenceirom a practical standpoint to make tests on a small pilot plant scale. Our reason for so: doing is that-We make one run, and only one, and that we have a complete series which shows the progressive effect of introducing the oxyalkylating agent, for instance, the ethyleneoxy radicals. Our preferred procedure is as follows: We prepare a suitable resin, or for that matter, purchase it in the open market. We employ 8 pounds of resin and 4 pounds of xylene and place the resin and xylene in a suitable autoclave with an open reflux condenser.

We prefer to heat and stir until the solution is for instance, 2% of caustic soda, in the form of a to solution, and remove the Water of solution or formation. We then shut off the reflux condenser and use the equipment as an autoclave only, and oxyethylate until a total of 60 pounds of ethylene oxide have been added, equivalent to 750% of the original resin. We prefer a temperature of about 150 C. to 175 C. We also take samples at intermediate points as indicated in the following table:

Pounds of Ethylene Oxide Added per Percentages 8-pound Batch Oxyethylation to 750% can usually be completed within 30 hours and frequently more quickly.

The samples taken are rather small, for instance, 2 to 4 ounces, so that no correction need be made in regard to the residual reaction mass. Each sample is divided in two. One-half the sample is placed in an evaporating dish on the steam bath overnight so as to eliminate the xylene. Then 1.5% solutions are prepared from both series of samples, 1. e., the series with xylene presout and the series with xylene removed.

Mere visual examination of any samples in solution may be sufficient to indicate hydrophile character or surface activity, i. e., the product is soluble, forming a colloidal sol, or the aqueous solution foams or shows emulsifying property. All these properties are related through adsorption at the interface, for example, a gas-liquid interface or a liquid-liquid interface. If desired, surface activity can be measured in any one of the usual ways using a Du Nouy tensiometer or dropping pipette, or any other procedure for measuring interfacial tension. Such tests are conventional and require no further description. Any compound having sub-surface-activity, and all derived from the same resin and oxyalkylated to a greater extent, i. e., those having a greater proportion of alkylene oxide, are useful for the practice of this invention.

Another reason why we prefer to use a pilot plant test of the kind above described is that we can use the same procedure to evaluate tolerance towards a trifunctional phenol such as hydroxybenzene or metacresol satisfactorily. Previous reference has been made to the fact that one can conduct a laboratory scale test which will indicate whether or not a resin, although soluble in solvent, will yield an insoluble rubbery product, i. e., a product which is neither hydrophile nor surface-active, upon oxyethylation, particularly extensive oxyethylation. It is also obvious that one may have a solvent-soluble resin derived from a mixture of phenols having present 1% or 2% of a trifunctional phenol which will result in an insoluble rubber at the ultimate stages of oxyethylation but not in the earlier stages. In other words, with resins from some such phenols, addition of 2 or 3 moles of the oxyalkylating agent per phenolic nucleus, particularly ethylene oxide, gives a surface-active product which is perfectly satisfactory, while more extensive oxyethylation yields an insoluble rubber, that is, an unsuitable product. It is obvious that this present procedure of evaluating trifunctional phenol tolerance is more suitable than the previous procedure.

It may be well to call attention to one result which may be noted in a long drawn-out oxyalkylation, particularly oxyethylation, which would not appear in a normally conducted reaction. Reference has been made to cross-linking and its effect on solubility and also the fact that, if carried far enough, it causes incipient stringiness, then pronounced stringiness, usually followed by a semi-rubbery or rubbery stage. Incipient stringiness, or even pronounced stringiness, or even the tendency toward a rubbery stage, is not objectionable so long as the final product is still hydrophile and at least sub-surface-active. Such material frequently is best mixed with a polar solvent, such as alcohol or the like, and preferably an alcoholic solution is used. The point which we want to make here, however, is this: Stringiness or rubberization at this stage may possibly be the result of etherification. Obviously if a difunctional phenol and an aldehyde produce a non-cross-linked resin molecule and if such mole cule is oxyalkylated so as to introduce a plurality of hydroxyl groups in each molecule, then and in that event if subsequent etherification takes place, one is going to obtain cross-linking in the same general way that one would obtain crosslinking in other resinification reactions. Ordinarily there is little or no tendency toward etherification during the oxyalkylation step. If it does take place at all, it is only to an insignificant and undetectable degree. However, suppose that a certain weight of resin is treated with an equal weight of, or twice its weight of, ethylene oxide. This may be done in a comparatively short time, for instance, at or C. in 4 to 8 hours, or even less. On the other hand, if in an exploratory reaction, such as the kind previously described, the ethylene oxide were added extremely slowly in order to take stepwise samples, so that the reaction required 4 or 5 times as long to introduoe an equal amount of ethylene oxide employing the same temperature, then etherification might cause stringiness or a suggestion of rubberiness. For this reason if in an exploratory experiment of the kind previously described there appears to be any stringiness or rubberiness, it may be well to repeat the experiment and reach the intermediate stage of oxyalkylation as rapidly as possible and then proceed slowly beyond this intermediate stage. The entire purpose of this modified procedure is to cut down the time of reaction so as to avoid etherification if it be caused by the extended time period.

It may be well to note one peculiar reaction sometimes noted in the course of oxyalkylation, particularly oxyethylation, of the thermoplastic resins herein described. This effect is noted in a case where a thermoplastic resin has been oxyalkylated, for instance, oxyethylated, until it gives a perfectly clear solution, even in the presence of some accompanying water-insoluble solvent such as 10% to 15% of xylene. Further oxyalkylation, particularly oxyethylation, may then yield a product which, instead of' giving a clear solution as previously, gives a Very milky solution suggesting that some marked change has taken place. One explanation of the above change is that the structural unit indicated in the following way where 811. is a fairly large number, for instance, 10 to 20, decomposes and an oxyalkylated resin representing a lower degree of oxyethylation and a less soluble one, is generated and 2, cyclic polymer of ethylene oxide is produced, indicated thus:

Hen

This fact, of course, presents no difficulty for the reason that oxyalkylation can be conducted in each instance stepwise, or at a gradual rate, and samples taken at short intervals so as to arrive at a point where optimum surface activity or hydrophile character is obtained if desired; for products for use in the practice of this invention, this is not necessary and, in fact, may be undesirable, i. e., reduce the efficiency of the product.

We do not know to what extent oxyalkylation produces uniform distribution in regard to phenolic hydroxyls present in the resin molecule. In some instances, of course, such distribution can not be uniform for the reason that we have not specified that the molecules of ethylene oxide, for example, be added in multiples of the units present in the resin molecule. This may be illustrated in the following manner:

Suppose the resin happens to have five phenolic nuclei. If a minimum of two moles of ethylene oxide per phenolic nucleus are added, this would mean an addition of 10 moles of ethylene oxide, but suppose that one added 11 moles of ethylene oxide, or 12, or 13, or 14 moles; obviously, even assuming the most uniform distribution possible, some of the polyethyleneoxy radicals would contain 3 ethyleneoxy units and some would contain 2. Therefore, it isjmpossible to specify uniform distribution in regard to the entrance of the ethylene oxide or other were to introduce 25 moles of ethylene oxide there is no way to be certain that all chains would have 5 units; there might be some having, for example, 4 and 6 units, or for that matter per molecule. resinification are employed or if such low-stage I resin is subjected to a vacuum distillation treatment as previously described, one obtains a 18 oxyalkylated products, distributions of radicals indicated are to be statistically taken. We have, however, included specific directions and specifications in regard to the total amount of ethylene oxide, or total amount of any other oxyalkylating agent, to add.

In regard to solubility of the resins and the oxyalkylated compounds, and for that matter derivatives of the latter, the following should be noted. In oxyalkylation, any solvent employed should be non-reactive to the alkylene oxide employed. This limitation does not apply to solvents used in cryoscopic determinations for obvious reasons. Attention is directed to the fact that various organic solvents may be employed to verify that the resin is organic solventsoluble. Such solubility test merely characterizes the resin. The particular solvent used in such test may not be suitable for a molecular or the like, rather than those which are soluble only in some other solvent containing elements other than carbon and hydrogen, for instance, oxygen or chlorine. Such solvents are usually polar, semi-polar, or slightly polair in nature compared with xylene, cymene, etc.

Reference to cryoscopic measurement is concerned with the use of benzene or other suitable compound as a solvent. Such method will show that conventional resins obtained, for example, from para-tertiary amylphenol and formaldehyde in presence of an acid catalyst, will have a'moleoular weight indicating 3, 4, 5 or somewhat greater number of structural units If more drastic conditions of resin of a distinctly higher molecular weight. Any molecular weight determination used, whether cryoscopic measurement or otherwise, other than the conventional cryoscopic one employing benzene, should be checked so as to insure that it gives consistent values on such conventional resins as a control. Frequently all that is necessary to make an approximation of the molecular weight range is to make a comparison with the dimer obtained by chemical combination of two moles of the same phenol, and one mole of the same aldehyde under conditions to insure dimerization. As to the preparationof such dimers from substituted phenols,

see'Carswell, Phenoplasts, page 31.

. 65. oxyalkylating agent. For that matter, if one The increased viscosity, resinous character, and decreased solubility, etc., of the higher polymers in j comparison with the dimer, frequently are all 3 or 7 units. Nor is there any basis for assuming that the number of molecules of the oxyalk lating agent added to each of the molecules of the resin is the same, or different. Thus, where formulae are given to I illustrate or depict the that is'required to-establish that the resin contains 3 or more structural 'units per molecule.

Ordinarily, the oxyalklation is carried out in autoclaves provided with agitators or stirring. de-

vices'.1 We have found that the speed of the agitation markedly influences the time reaction.

Ins'ome cases; the change fom slow speed agitation for example, in a laboratory autoclave agitation with a stirrer operating at a speed of 60 to 200 R. P. M., to high speed agitation, with the stirrer operating at 250 to 350 R. P. M., reduces the time required for oxyalkylation by about one half to two-thirds. Frequently xylene-soluble products which give insoluble products by procedures employing comparatively slow speed agitation, give suitable hydrophile products when produced by similar procedure but with high speed agitation, as a result, we believe, of the reduction. in the time required with consequent elimination or curtailment of opportunity for curing or etherization. Even if the formation of an insoluble product is not involved, it is frequently advantageous to speed up the reaction, thereby reducing production time, by increasing agitating speed. In large scale operations, we have demonstrated that economical manufacturing results from continuous oxyalkylation, that is, an operation in which the alkylene oxide is continuously fed to the reaction vessel, with high speed agitation, i. e., an agitator operating at 250 to 350 R. P. M. Continuous oxyalkylation, other conditions being the same, is more rapid than batch oxyalkylation, but the latter is ordinarily more convenient for laboratory operation.

Previous reference has been made to the fact that in preparing esters or compounds of the kind herein described, particularly adapted for demulsification of water-in-oil emulsions, and for that matter for other purposes, one should make a complete exploration of the wide variation in hydrophobe-hydrophile balance as previously referred to. It has been stated, furthermore, that this hydrophobe-hydrophile balance of the oxyalkylated resins is imparted, as far as the range of variation goes, to a greater or lesser extent to the herein described derivatives. This means that one employing the present invention should take the choice of the most suitable derivative selected from a number of representative compounds, thus, not only should a variety of resins be prepared exhibiting a variety of oxyalkylations, particularly oxyethylations, but also a variety of derivatives. This can be done conveniently in light of which has been said previously. From a practical standpoint, using pilot plant equipment, for instance, an autoclave having a capacity of approximately three to five gallons. We have made a single run by appropriate selections in which the molal ratio of resin equivalent to ethylene oxide is one to one, 1 to 5, l to 10, 1 to 15, and 1 to 20. Furthermore, in making these particular runs we have used continuous addition of ethylene oxide. In the continuous addition of ethylene oxide we have employed either a cylinder of ethylene oxide without added nitrogen, provided that the pressure of the ethylene oxide was sufficiently great to pass into the autoclave, or also we have used an arrangement which, in essence, was the equivalent of an ethylene oxide cylinder with a means for injecting nitrogen so as to force out the ethylene oxide in the manner of an ordinary seltzer bottle, combined with the means for either weighing the cylinder or measuring the ethylene oxide used volumetrically. Such procedure and arrangement for injecting liquids is, of course, conventional. The following data sheets exemplify such operations, i. e., the combination of both continuous agitation and taking samples so as to give five diiferent variants in oxyethylation. In adding ethylene oxide continuously, there is one precaution which must be ide must stop immediately if there is any indication that reaction is stopped or, obviously, if reaction is not started at the beginning of the reaction period. Since the addition of ethylene oxide is invariably an exothermic reaction, whether or not reaction has taken place can be judged in the usual manner by observing (a) temperature rise or drop, if any, (1:) amount of cooling water or other means required to dissipate heat of reaction; thus, if there is a temperature drop without the use of cooling water or equivalent, or if there is no rise in temperature without using cooling water control, careful investigation should be made.

In the tables immediately following, we are showing the maximum temperature and usually the operating temperature. In other words, by experience we have found that if the initial reactants are raised to the indicated temperature and then if ethylene oxide is added slowly-this temperature is maintained by cooling water until the oxyethylation is complete. We have also indicated the maximum pressure that we obtained or the pressure range. Likewise, we have indicated the time required to inject the ethylene oxide as well as a brief note as to the solubility of the product at the end of the oxyethylation period. As one period ends it will be noted we have removed part of the oxyethylated mass to give us derivatives, as therein described; the rest has been subjected to further treatment. All this-is apparent by examining the columns headed Starting mix, Mix at end of reaction, Mix which is removed for sample, and Mix which remains as next starter.

The resins employed are prepared in the manner described in Examples 1a. through 10311. of our said Patent 2,499,370, except that instead of being prepared on a laboratory scale they were prepared in 10 to l5-gallon electro-vapor heated synthetic resin pilot plant reactors, as manufactured by the Blaw-Knox Company, Pittsburgh, Pennsylvania, and completely described in their Bulletin No. 2087 issued in 1947, with specific reference to Specification No. 7l3965.

For convenience, the following tables give the numbers of the examples of our said Patent 2,- 499,370 in which the preparation of identical resins on laboratory scale are described. It is understood that in the following examples, the change is one with respect to the size of the operation.

The solvent used in each instance was xylene. This solvent is particularly satisfactory for the reason that it can be removed readily by distillation or vacuum distillation. In these continuous experiments the speed of the stirrer in the autoclave was 250 R. P. M.

In examining the subsequent tables it will be noted that if a comparatively small sample is taken at each stage, for instance, ,4; to one gallon, one can proceed through the entire molal stage of l to l, to l to 20, without remaking at any intermediate stage. This is illustrated by Example 10411.. In other examples we found it desirable to take a larger sample, for instance, a 3-gal1on sample, at an intermediate stage. As a result it was necessary in such instances to start with a new resin sample in order to prepare sufficient oxyethylated derivatives illustrating the latter stages. Under such circumstances, of course, the earlier stages which had been previously prepared were by-passed or ignored. This is illustrated in the tables where, obviously, it shows that the starting mix was not removed from a previoussample."

Date

PhenoZ forum..- Phra ter tiary"amylphenol [Resin'made'i'n pilot pleint'size betel approximately 25 poun' 'ds',.eorrespon Aldehyde for resin? Formaldehyde ding to 3d of Patent 2,49%);370 but. thisbatch designated 1040.]

s Mix Which is Mix Which Re- Starting Mix i Removed for- V mains as Next Reaction Sample Starter Max. Max. Time Pressure, Temp erahrs Solubility Lbs. 'L'b's'. Lbs. Lbs. Lb Lbs. Lbs. Lbs Lbs. Lbs. Lbs q- W Sol- Res- Sol- ;Res- Eto'l -Sol- Res- Sol- Resvent in vent in vent 1n vent in First Stage Resin to EtO Molal Ratio 1:1 14.25 15.75 "0 14.25 15.75 4.0' 3.35 -3.65 1.0- 10.9 12.1- 3.0 80 150 34 I Ex. No. 104D...

Second Stage Resin to Et0 M01211 Ratio 1:'5 10. 9 12.1 3.0 10. 9 12.1- 15.25 3. 77 4.17 5.31 7.13 7.93 9.94 70 158 M ST Ex. No. 105b Third Stage Resin to EtQ. L MolalRatio 1:10. 7. 13 7. 93 '9. 94 7.13 7. 93- 19. 69 3.29 3. 68 9. O4 3. 84 4. 10.65 G0 173 FS Ex. No.106b I Fourth Stage Resin to EtO k Mola] Ratio 1:15- 3584 4. 25 -10.65 3. 84 4; 25 16. 15- 2. 04 2.21 8-. 1. 80 2.04 7.60 220 160 $6 RS EX. N0. 107b Fifth Stage I Resin to Et0 Molal Ratio 1:20- L80 2. 04 '7. 1.80 2.04 10.2 100 -l50 QS Ex. No. 108b I= Insoluble. ST Slight tendency toward becoming soluble. F S Fairly soluble.

R S= Readily soluble. QS= Quite soluble.

Date Phenol for res i rt: N ony lpherwl Aldehyde for resin." Forrhlzldehyde [Resin made in pilot plant size batch, approximately 25 pounds, eorres'pon'ding to a of Patent 2,499187dbut this batch designated 10911.]

- s Mix Which'is Mix Which Re- Starting Mix fig; Egg Removed for mains as Next 0 Sample Starter Max. Max. Time Pressure, Temp erahrs. Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. 9-

Lbs. Lbs. Lbs. Lbs. Sol- Res- Eto Sol- Res- Eto Sol- Res- Eto Sol- Res- Eto vent v in vent in vent in vent in First Stage Resinto EtO b10181 Ratio 1: 15. O 15. O O 15. 0 15. O 3 5. U 5. O 1. 0 v 10. 0 10. U 2.0 50 150 1% ST X N0.109b

Second Stage Resinto EtO i 3 l Molal Ratio 125." 10 10 2. 0 1O 10 9. 4 2. 72 2. 72 2. 56 7. 27 7. 27 6. 86 147 2 DT Ex. No.l10b.

Third Stage Resin to EtO M0181 Ratio 1:10-. 7. 27 7. 27 6. 86 7. 27 7. 27 13. 7 4. 16 4. 16 7. 68 3. 15 3. 1'5 5.95 1% S Ex. No. 11lb.

Fourth Stage Resin to E170... V b M0181 Ratio 1:15-. 3. l5 3. 15 5. 95 3- 15 3. 15 8. 95 1. 05 1. 05 2. 95 2. 10 2. 10 6. 00 220 174 2% S Ex. N0.1l2b

Fifth Stage Resint0Et0 i M0131 Ratio 1 :20 2. 1O 2. 1O 6. 00 2'.10 2. 1O 8. 00 220 183 VS I E21. No.113b.

S=Soluble. ST=S1ight tendency toward solubility. DT=Deflnlte tendency toward solubility. VS=Very soluble.

Date

Phenol fortresin: Para-octylphenol [Resin made in pilot plant size but Aldehyde for resin: Formaldehyde ch, approximately 25 pounds, corresponding to So of Patent 2,499,370 but this batch designated 114m] Mix at End of Reaction Mix Which is Removeu for Sample Lbs Lbs.

Lbs Sol- Resvent. in Eto Lbs. Lbs. S01- Res;- Lbs vent in Pressure, 1bs.sq. in. ture, C.

Etd

Resinto EtO MolaiRatio 1:15.-

Ex. No. 117b.

Fifth Stage Resin to EtO..

Moial Ratio 1: 20.- Ex. N01 1180.

Date

NS=Not soluble.

Phenol for resin: M enthylphenol [Resin made in pilot plant size batch, approximately pounds, corresponding to 690. of Patent 2,499,370 but th VS ==Very soluble.

Aldehyde for resin: Formaldehyde Mix Which is is batch designated 11911.]

Mix at End 0! Removed ior Reaction Sample Max.

lgressuxie, "zlempeissv sq. n. ure, Lbs. Lbs. Lbs. Lbs. Lbs Soi- Res- Etc 801- Res- Eto vent in vent in First Stage Resin to Eton... M0181 Ratio 1:1 13. 65 16. 9. 11. 45 2. 1 Ex. No;{119b Second Stage Resin to EtO. Molai Ratio 1:5..- 12 4. 52 5. 42 4. 81 140 Ex. No. 120b-.-

Third Stage to Et0.. M0181 Ratio 1:10-. 5. 48 6. 58 10.85 90 160 Ex. No. 12lb-.

Fourth Stage Resin to Et0.... Moial Ratio 1:1 4. 1 4.9 13. 15 180 171 Ex. No.122b.- Fijtti Stage Resin 1.6mm--- Molsl Ratio 1:20.- 3.10 3. 72 13.43 320 Ex. No. 1231:..

B=Soiuble. NS=Not soluble. VS=Very soluble.

Phenol for resin: Para-secondary butylphenol Aldehyde for resin: Formaldehyde Date [Resin made in pilot plant size batch, approximately pounds, corresponding to 2a of Patent 2,499,370 but this batch designated 12411.]

Mix Which is Mix Which Re- Starting Mix figg fi g of Removed for mains as Next Sample Starter Max. Max. Time Pressure, Temperahrs Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs.

Lbs. Lbs. Lbs. Lbs. Sol- Res- Eto Sol- Res- Eto Sol- Res- Eto Sol- Res- Eto vent in vent in vent in vent in First Stage Resin to EtO Molal Ratio 1:1 14. 15. 0 14.45 15. 55 4. 25 5. 97 6.38 1. 75 8.48 9. 17 2. 50 150 12 NS Ex. N0. 124b-.

Second Stage Resin to Et0 Molal Ratio 1:5 8 48 9.17 2.50 8. 48 9.17 16. 0 5. 83 6.32 11. 05 2.65 2. 85 4. 95 95 188 14: SS Ex. N0. 125b Third Stage Resin to EtO. Molal Ratio 1:10.. 4. 82 5. 18 0 4. 82 5. 18 14. 25 400 183 M S Ex. N0. 1266.

Fourth Stage Resin to EtO. Molal Ratio 1:15.. 3. 85 4.15 0 3. 85 4. 15 17.0 120 180 3!; VS Ex. N0. 127b- Fifth Stage Resin to Et0... Molal Ratio 1:20.. 2 2. 4. 2. 65 2. 85 15. 45 80 170 1: VS Ex. No. 128b S=Soluble. NS=Not soluble. SS=Somewhot soluble. VS =Very soluble.

Phenol for resin: Menthyl Aldehyde for resin: Proptonaldehyde Date [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 81a of Patent 2,499,370 but this batch designated 12911.]

. Mix Which is Mix Which Re- Starting Mix 23; E of Removed for mains as Next G on Sample Starter Max. Max. Time Pressure, Temp erahm Solubility Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs lbs-8919' Sol- Res- Sol- Res- Sol- Res- Sol- Resvent in vent in vent in vent in First Stage Resin to EtO.-- M0131 Ratiohl... 12 8 17.2 12.8 17. 2 2.75 4. 25 5. 7 0.95 8.56 11.50 1.80 150 3% Not soluble. EX.No.129b-- Second Stage Resin to EtO. Molal Ratio 1:5 8 55 11. 50 1.80 8. 55 11.50 9.3 4. 78 6.42 5.2 3.77 5.08 4.10 100 170 Ma Somewhat Ex. No. b soluble.

Third Stage Resin to EtO M01211 Ratio 1:10.. 3. 77 5. 08 4. 10 3. 77 5. 08 13. 1 100 182 M2 Soluble. Ex. N0. 131b Fourth Stage Resin to EtO Molal Ratio 1:15 5 2 7.0 6. 2 7.0 17. 0 2.10 2.83 6. 87 200 182 A Very soluble. Ex. No. 132b Frfth Stage Resin to Et0 Mo1a1Ratio1:20 2 10 2 83 6 87 2 l0 2 86 9.12 90 56 D0 Err. No .133b

Date

[Resin made on pilot plant size batch, approximately 25 pounds, oorre Phenol for resin: Para-tertiary amylphenol Aldehyde for main: Furf ural sponding to 42a of Patent 2,499,370 but this batch designated as 134m] Mix at End of Reaction Mix Which Remains as Next Starter Lbs. Lbs. Lbs. EtO

Sol- Resvent 1n EtO EtO Lbs. Lbs. Lbs. Lbs. Sol- Res- Eto vent 111 First Stage Resin to 15130...- M0131 Ratio 1:1 Ex. No. 134b..

Second Stage Resin to EtO Moiai Ratio 1:5... Ex. N0. 135D"...

Third Stage Resin to 131130.... Molal Ratio 1:10.. Ex. No. 1361;..."

Fourth Stage Resin to EtO Molal Ratio 1: 15 Ex. No. 1375.

Fifth Stage Resin to EtO.

M0131 Ratio 1:20.- EX. N0. 138b Date [Resin made on pilot size batch, approximatel Phenol for resin: M enthyl Aldehyde for resin: Furfw'al y 25 pounds, corresponding to 89a of Patent 2,499,370 but this batch designated as 13911.]

Mix at End of Reaction Mix Which Remains as Next Starter Lbs vent 112.

vent m First Stage Resin to 15120. Molal Ratio 1:1 Ex. N0. 1390.

Second Stage Resin to EtO- Molai Ratio 1 :5 Ex. No. 1405.

Third Stage Resin to EtO--- Molai Ratio 1:10.- Ex. No. 141b Fourth Stage Resin to Et0 Mala] Ratio 1:15.. Ex. No. 1425 Fifth Stage Resin to EtO Molal Ratio 1: 20 Ex. No. 14%.

Date

' Phenol forresin: Para-'actyl Aldehyde-for resin: Furfuml s, corresponding to 42a of Patent 2,499,370 with 206 parts'by weight of commercial ts by weight of papa-tertiary amylphenol but this batch designated as 144a] Y Mix Which is Mix Which Re- Starting Mix f gg fi g Removed for mains as Next 1 Sample Starter Max. Max. Time Pressui e, Temp erahm Solubility lbls. Ifibs. Lbs 1 .11;. gbs. Lbs IbIs. abs. I b I bs. Lbs 01 o eso eso eso esvent in Eto vent in mo vent in Eto vent in Eto First Stage Resinto mom. Molal Ratio 1:1.-- 12.1 18. 6 12.1 18. 6 3.0 5. 38 8.28 1. 34 6. 72 10. 32 1. 66 80 150 M2 Insoluble. Ex. No. l44b- Second Stage Slight tend- Resin to Et0- ency to- Molal Ratio 1:5.-- 9.25 14. 25 9. 25 14. 25 11. 0 3. 73 5. 73 4. 44 5. 52 8.52 6. 56 100 177 i2 Ward. be- Ex. No. 14517-.- coming soluble.- Third Stage Resin to EtO- 1 r M0181 Ratio 1: 6. 72 10. 32 1. 66 6. 72 10. 32 14. 91 4. 97 7. 62 11.01 1. 75 2. 70 3. 90 85 182 V4 Fairly. solu- Ex. No. 14Gb--." ble.

Fourth Stage Resin to EtO 11,. Molal Ratio 1:15.- 5.52 8. 52 6.56 5. 52 8.52 19.81 100 176 7% Readilysolu- Ex. No. 1476"... ble.

Fifth Stage Resinto 1360---- Molal Ratio 1:20 1. 75 2. 70 3.90 1. 75 2. 70 8. 4 80 160 V1 Quite 8011].- Ex. No. 148b ble.

Phenol for resin: Para-phenyl Aldehyde for resin: Furfural Date [Resin made on pilot plant size batch, approximately 25 p paraphenylphenol replacing 164 parts b ounds, correspondi g to 42a of Patent 2,499,370 with 170 parts by weight of commercial y weight; oipera-tertlary amylphonol but this batch designatedas 14911.1

. Mix Which 18 Mix Which Re- Starting Mix fig: Egg of Removed [or mains as Next Sample Starter M Max Pressure, Temp era Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. S Res- Sol- Res- Sol- .Res-

S'ol- Resvent in vent in vent in vent in First Stage Resin to EtO M0181 Ratio 1: 1-.- l3. 9 1G. 7 13. 9 16. 7 3. 0 3. 5O 4. 0. 8O 10. 12. 2. 20 100 160 K; Insoluble. Ex. N0. 1496- Second Stage Resin to Et0 251; 1 31 M018] Ratio 1:5... 10. 35 12. 45 2. 20 10. 35 12. 45 12. 20 5. 15 6. 19 6. O6 5. 20 6. 26 6. 14 183 in; g 5011* Ex No. 1505.....

' bihty.

Third Stage Resinto Et0- M0131 Ratio 1: 10.. 8. 9O 10. 7 8. 10. 7O 19. 0- 5. 3D 6. 38 11. 32 3. 6O 4. 32 7. 68 90 193 A2 Fairly S0111- Ex. No. 1515--." ble. 7

Fourth Stage Resin to mom- M0181 Ratio 1: 15.. 5. 20 G. 26 6. 14 5. 2O 6. 26 16. 64 171 P6 Readlly S01- Ex. No. 152b uble.

Fifth Stage Resin to EtO p Sample somewhat rubbery and gela- 3. 60 4. 32 7. 68 3. 6O 4. 32 15. 68 tinous but fairly soluble 230 2 Phenol for min.- Pammonylphenol Aldehyde for 1-esrin': Furfural Date [Rosin made on pilot plant size batch .apprdximate1y pounds, corresponding to 8841 oft Patent 2,499,370 but this batch designated as 15411.]

' Mix Which is Mix Which Re- Starting Mix figg fi g or Removed for mains as Next Sample Starter Man Man Pressuxe, Temp era- E? Solubility Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. mmf Sol- Res- 801- Res- 801- Res- Sol- Resvent in vent in vent in vent in First Stage Resin to EtO. M0181 Ratlolzl }10.85 20. 10.85 20. 75 3.0 2.57 4.90 0. 73 8.28 15.85 2.27 $6 Insoluble. Ex. No. 15411"..- v j Second Stage Slight tend- Resin to Et0-. ency to- Molal Ratio 1: 8.28 15.85 2.27 8.28 15:85 11.77 3.82 7.33 5.45 4.46 8.52 6.32 100 182 )6 Ward ba- Ex. No. 1555.. coming soluble. Third Stage Resin to EtO M0131 Ratio1:10 5 95 11.35 5.95 11.35 15. 75 3.38 6.42 9.50 2. B7 4.93 7.25 100 181 16 Fairly solu- Ex. No. 156b. ble.

Fourth Stage Resin to Et0 Molal Ratio1:16-- 4 46 8.52 6.32 4. 46 8.52 19. 07 90 188 18 Readily sol- Ex. No. 1570.--" uble.

Fifth Stage Basin to EtO--. Molal Ratio 1:20.- 2 57 4.93 7.25 2.57 4.93 14. 50 100 160 $6 Quitasolu- Ex. No.158b--... ble.

Phenol for resin: Para-phenylphenol Aldehyde for resin: Formaldehyde Date [Resin made on pilot plant size batch, approximately 25 pounds, oorrsponding to 9a of Patent 2,499,370 but this batch designated as 1591;]

I Mix Which which RB. Starting Mix g fi g of Removed for mains'as Next Sample Starter Max llgressm e, gemaergfi Solubility Lbs Lbs. Lbs. Lbs. Lbs. Lbs. 'Lbs. Lbs.

Lbs. Lbs. Lbs. Lbs. Sol- Res- 801- Res- Sol- 328- 801- Resvant in Etc vent in Em vant in mo vant in Em First Stage Resin to EtO-- Molal Ratio 1:1... Ex. No

Second Stage V Resin to EtO Molal Ratio 1: 11.0 2.0 11.0 9.0 11.75 7.6 6.2 8.11 3.41 2.80 3.64 160 188 y. Insoluble. Ex. No. 15%..."

Thir dStoae v t Resin to 15110. Molal Ratio 1:10 Ex. No.

;'Fo'u.rth Stage Resin to Et0 Molal Ratio 1:15.- Ex. No

Fifth sum Resin to EtO Molal Ratio 1:20.. 3 41 2.80 3.64 3.41 2.80 13.64 B0 34 Soluble. Ex. N0. 1605.--"

Date

[Resin made on pilot plant size batch approximatelyfi pounds, eorresponding to 42a of Patent 2' para-secondary butylphenol replacing 164 parts by weight of para- Phenol for resm: Para-secomlai'y 'butylphenol Aldehyde for resin: Fu'rfural V p 499,370 with 1;50.pai tsby weight commercial tertiary amylphenol but this batch designated as 1615.]

wh ch is Mix which Re- Startlng Mix fig figg of Removed for mains as Next Sample Starter Max Max 1 Tifne P ressu e, Tem ge a- Solubility Lbs. Lbs. Lbs. Lbs. Lbs. bs. Lbs. Lbs.

. Lbs. Lbs. Lbs. Lbs. Sol- Res- Eto Sol- Res- Eto S01 Res- Sol- Res- Eto vent in I vent in vent in vent in First .Stage Resinto Et0.... Molal Ratio 151.. 12.0 17.9 12.0 17. 9 3. 5 2. 65 3. 98 0.77 9.35 13. 92 2. 73 150 -171 $6 Inboliible. Ex. No.161b Secoui Stage Slight tend- Resinto EtO- H p enc y 'tb- MolalRatio 1:5. 9. 35 13. 92 2. 73 9. 35 13. 92 13. 23 5. 00 7. 42 7. 08 4. 35 6. 50 6. 100 192 W'ai'd be- Ex. No. 162b. bininseluble. Third Stage Resin to EtO.. A M0181 Ratio 1:10 6. 8. 95 6. 25 8. 95 17. 0 3. 23 4. 61 8. 76 3. 02 4. 34 8. 24 120 188 M2 Ffiii ly 351L1- EX. N0. 163b bl.

Fourth Stage ResintoEtQ-,,- ,v M0101 Ratio 1:15. 4. 6.50 6.15 4.35 6. 13. 40 181 l RilfilTy S01- Ex. No. 164b. ubl.

Fifth Stage Resin to E tQuh p 7 Sample somewbgt-rubber'yendgeletp Mclal Ratio 1:20. 3.02 4. 34 8 24 3.02 4.34 16.49 1110115 but Shows liinit'ed watei S01- 161' 94 Ex. No. 16515;.... ubillity. I I l Phenol for resin: Para-octylphenol Aldehyde for resin: Propz'onaldehyde Date [Resin made on pilot plant size batch, approximately 25 pounds, con-es pai'a-octylphenol replacing 164 par ponding to 34a of Patent 2,499,370 ts by weight of para-tertiary amylphenol but this b with 206 parts by weight of commercial atch designated as 166a.]

: Mix Which is Mix Which Re- Starting Mix figg figg of Removed for mains as Next Sample Starter Max. Max. Time Pressu e, Temp ei-a-. hrs Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs Lbs. Lbs. Lbs Sol- Res- Sol- Res- Sol- Res- 801- Res vent in vent in vent in vent in First Stage Resin to Et0.... Molal Ratiohl... 13.3 16.9 13.3 16.9 3.0 3.1 4.0 0.70 10.2 12.9 2.3 100 $4; Insoluble. Ex. N0.166b.-.

Secom Stage Resin to EtO Mola1Ratlo1:5 10.2 12.9 2.3 10.2 12.9 11.3 6.34 8.03 7.03 3.86 4.87 4. 27 100 166 V4 Becoming EX. N0. 167b 301111318.-

Third Stage Resin toEtORN Molal Rati01:1l.3 6. 46 8.24 6. 46 8.24 16.5 3.52 4.49 8.99 2.94 3.75 7. 51 80 177 $4 Fairly solu- Ex. No.168bble.

Fourth Siage Resin to EtO Molal Ratio1:15 3.86 4.87 4.27 3.86 4. 87 13.02 80 204 V4 Readily sol- Ex. No. 169b nble:

Fifth Stage Resin to Etdi." Molal Rati01:20 2.94 3.75 7.51 2.94 3.75 13.26 100 150 $4 Soluble. Ex. N0.170b

phe'ri'ol'for resin: Para-manylphenol Aldehyde for resin: Pr'piondldeirgde Date IB'esin made on pilot plant size batch. approximately 25 pounds, corresponding to 82a of Patent 2,499,370 but this batch designated as 1710.]

Mix Which is Mix Which Re- Starting Mix fig figg of 1 Removed for mains as Next Sample Starter Max. Max. Time I A 1lgessure, 'tiemo eighrs Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Sol- Res- Sol- Res- Sol- Res Sol- Resvent in vent in vent in vent; in

First Stage Resin to EtO. Molal Ratio 1:1.-. 10.9 18.0 10. 9 18.0 3.0 2. 65 4.4 0.75 8. 25 13.60 2. 25 120 150 M2 Insoluble." Ex. No.171b..

Second Stage Resin to 11120...- Molal Ratio 1:5... 8. 25 13. 60 2. 25 8. 25 13. 60 11. 50 5. l 8. 35 7. 05 3. 5. 4. 95 174 56 Becoming Ex. No. 1725"... soluble.

Third Stage Resin to EtO.... M0181 Ratio 1:10.. 5. 9. 35 5.. 65 9. 35 15. 3. 71 6. 14 10. 35 1. 94 3. 21 5. 40 90 182 12 Fairly Ex. N0. 173b.-. soluble.

Fourth Stage 7 Resin to EtO. Molal Ratio1:l5.- 3 15 5.25 4.45 3.15 5.25 13. 45 182 Readily Ex. No. 1740. soluble.

Fifth Stage Resin to mo..- Molal Ratio 1:20.. 1 94 3.21 5. 40 l. 94 3. 21 10. 65 150 )6 Soluble. Ex. No. 1755..

Phenol for resin: Pam-tertiary amylphenol Aldehyde for resin: Propionaldeh'yde Date [Resin mode on pilot plant size batch, approximately 25 pounds, corresponding to 34a of Patent 2,499,370 but this batch designated as 176a.]

Mix Which is Mix Which Re- Starting Mix figg figg of Removed for mains as Next Sample Starter v Max. Max. Time lPbressure, llemp elg hrs Solubility Lbs Lbs Lbs. Lbs. Lbs. Lbs. Lbs. Lbs.

Lbs Lbs. Lbs. Lbs. Sol- Res- Sol- Res- 801- Res- 501- Resvent in Eto vent in Eto vent in Eto vent in Eto First Stage Resinto Et0.... M0181 Ratio 1:1... 12 6 16. 2 12. 6 16. 2 3. 5 3. 08 3. 96 0. 86 9. 52 12. 24 2. 64 M2 Insoluble. Ex. No.176b....-

Second Stage Resin to EtO.. Moial Ratio 1:5... 9. 52 12. 24 2. 64 9. 52 12. 24 12. 89 5. 27 6. 79 7. 14 4. 25 5. 45 5. 75 85 171 Ms B 60 0 min g Ex. No. 1775..... soluble.

Third Stage Resinto EtO Molal Ratio 1:10-- 6 5 8. 3 6. 5 8. 3 17. 76 3. 81 4. 87 10. 42 2. B9 3. 43 7. 33 120 183 $6 Fairly solu- Ex. No. 1785..... ble. 7

Fourth Stage Resin to Et0 Molal Ratio 1:15.. 4 25 5. 45 5. 75 4. 25 5. 45 17. 25 85 196 56 Readily sol Ex. No. 179b uble.

' Fifth Stage Resin to EtO.... Molai Ratio 1:20. 2. 69 3. 43 7. 33 2. 69 3. 43 14. 55 95 $6 Soluble. Ex. No. 180b.-...

37 PART 3 Drastically-oxidized dehydrated castor oil fatty acids are the acids present in glyceride form in drastically-oxidized dehydrated castor oil. It is well known that castor oil which has not been subjected to pyrolytic dehydration may be oxidized in various manners.

This is usually accomplished by subjecting a ricinoleic compound to treatment, such as blowing with a suitable gaseous oxidizing medium, i. e., air, oxygen, ozone, or ozonized air. Such oxidation is commonly carried out at ordinary or super atmospheric pressure (up to about 200 pounds per square inch) either moist or dry; and in the presence of or absence of a catalyst, such as lead oleate, cobalt linoleate, or manganese oleate, or such as alpha-pinene or linseed oil, etc. Care should be taken, however, not to permit temperature rise such that excessive pyrolytic decomposition would take place. The oxidation may be vigorous, as by vigorous blowing, or may be more gradual, as by exposure in thin films to air, provided the oxidation is sufliciently prolonged to obtain the desired drastic oxidation. Usually, the time required is at least about 8 to 10 hours under conditions most favorable to oxidation, 1. e., blowing at a relatively high temperature, and for certain fatty compounds much more prolonged oxidation, i. e., several days, or even weeks, is desirable, especially under conditions less favorable to rapid oxidation. In any event, whether the oxidation is produced by continued mild oxidation, or by more vigorous oxidation, 2. condition of drastic oxidation is indicated by changes in chemical and physical attributes of the material. These changes are usually indi- Gated by a lowered iodine value, an increased saponification value, usually an increased acetyl value, an increased specific gravity, and an increased refractive index. Thus, the iodine number may become less than 70, and even as low as about 40. The saponification value may be about 215 to about 283, and the acetyl value may be about 160 to about 200. The viscosity is in-- creased and the drastically-oxidized product may become very heavy and stiff at ordinary temperature. The refractive index is also increased. The color of the drastically-oxidized material may be a, pale yellow or light amber, or may be a deep orange color. If oxidation is carried on long enough, a product of liver-like consistency and dark color is obtained.

. The same sort of procedure which is used to mg, considerably less drastic conditions are re-'-- quired. Furthermore, the time element can be decreased greatly. The same sort of apparatus and the same sort of procedure is employed as in the case of conventional oxidation of castor oil. Since dehydrated'castor oil is already polymerized to a greater or lesser degree, and perhaps has initial viscosity considerably greater than that of castor oil, it is obvious that the final stages of ducted until there is a significant change, as indicated by increased viscosity, change in such indices as iodine number, hydroxyl number. etc., all of which is obvious to those skilled in the art. As a matter of fact, unless one desires to do so, there is no need to oxidize such dehydrated castor oil, insofar that various products of this kind are sold commercially and used in other arts which have no particular connection with the usage herein contemplated.

Castor oil or similar materials of the kind described have been dehydrated and such dehydrated materials used for various other purposes,

for instance, as substitutes for drying oils, as plasticizers in the manuracture or resins, as ingredients entering into the com ounding of insulating materials, etc. Generally speaking, the conventional procedure is to subject a quantity of castor oil to destructive distillation, at approximately 250-310" C., and generally, 250-285 C., until at least 5-15'% of the original volume has been removed as a distillate. Sometimes the procedure is conducted primarily to recover the distillate, due to its high content of heptaldehyde. Generally speaking, the lower limits of the material distilled 011 are approximately 840%, and the upper limits, possibly 15-23%. In some instances, pyrolysis is conducted in presence of an added catalyst, which may permit the reaction, i. e., the degradation or destructive distillation, to take place at lower temperature; and sometimes vacuum is employed, or both vacuum and a catalyst. Such procedure of subjecting a ricinoleic acid compound, and especially ricinoleic oxidize ricinoleic acid compounds, such as castor oil, which have not been subjected to pyrolytic dehydration, such as ordinary castor oil of commerce, may also be employed to oxidize dehydrated castor oil, or similar material of the kind herein intended as a primary raw material. Generally speaking, the following modifications should be kept in mind:

Such materials are apt to contain at leasta significant amount of decadiene 9,11-a'cid-1 or its ester, which is recognized as a powerful catalyst for promoting oxidation of castor oil or similar materials. Thus, it is rarely necessary to add any catalyst to hasten oxidation. Furthermore, it is rarely necessary to oxidize under pressure, although such procedure may be employed. It is rarely necessary to use oxygen instead of air. It is rarely necessary to oxidize at a temperature above 120 C. Thus, notwithstanding the fact that any of the usual procedures employed for oxidizing castor oil may be employed for oxidizingdehydrated castor oil, yet generally spealcacid or castor oil, to pyrolysis, is so well known that no further elaboration is required. However, for convenience, reference is made to the following patents, which clearly describe the procedure, and in 'some'instances, point out at least some of the complicated chemical changes that take place: U. 8.. Patents Nos. 1,240,565,- September 18, 1917, Harris; 1,749,463., March 4, 1930, Bertsch; 1,799,420, April 7, 1931, Holton; 1,892,258, December 2'7, 1932 Ufer; 1,886,538, November 8, 1932, Fanto; 2,156,737, May 2, 1939, Priester; 2,195,225, March 26, 1940,'Priester;and British Patent 306,452, May 9, 1930, Scheiber.

vAs to a comparative evaluation of various dehydration catalysts for castor oil, see Masloboino zhirovanya Prom. 16 No. 5/6, 33-8 (1940);

The products which we prefer to use as reactants in the present instance, are blown dehydrated castor oils having substantially the following identifying characteristics within the ranges indicated:

Reichert-Meisel number Less than 5 Acetyl number Per cent unsaponifiable number Generally less than 3% Per cent nitrogen 0.0% Per cent SO: 0.0% Per cent ash Trace Specific gravity at 31 C bout 0.9574 Refractive index at 31 C About 1.495

Color Straw or light amber A specific example of a very desirable oxidized dehydrated castor oil for use in the practice of this invention, and which is available in the open market, has approximately the following specific characteristics:

Per cent unsaponifiable matter Less than 2.5%

Per cent nitrogen 0.0 Per cent S02 0.0 Per cent ash Trace Specific gravity at 31 C. 0.9574 Refractive index at 31 C 1.4795

The above values or similar values are of assistance in indicating and characterizing a material of the kind herein contemplated. For in stance, although the entire chemistry of the dehydration of castor oil is not known, yet obviously there must be a marked reduction in the acetyl or hydroxyl value, and simultaneously an increase in the iodine value. Also, such pyrolytic reaction tends to eliminate thelow molal or volatile acids. On oxidation of such material, the acetyl value or hydroxyl value may stay constant or increase. But in any event, the iodine value is reduced until it begins to approximate that of castor oil or ricinoleic acid prior to dehydration, or somewhat lower. The fact that the acetyl value or hydroxyl value does not increase proportionally with the drop in the iodine value is, of course, due to either the formation of other type compounds, or oxides which do not give a hydroxyl or acetyl value, or else, due to the formation of ester acids or similar reactions. It is generally desirable that the iodine number of the drastically-oxidized dehydrated castor oil be not less than 70, that the saponification value be within the range of 195 to 200, and that the acetyl value be within the range of 60 to '15.

Reactions, intended to introduce the acid radicals of blown dehydrated castor oil into the oxyalkylated resin compound of the kind previously described, may involve procedures analogous to those described in our co-pending application, Serial No, 64,454, filed December 10, 1948, now Patent No. 2,541,995, issued February.20,'195l. For instance, one may obtain the fatty acids in the usual manner, i. e., by acid saponification, or by alkaline saponification followed by oxidation. One may react such fatty acids with lowmolal alcohol, such as methyl or ethyl alcohol and produce esters by the elimination of such alcohol. However, acidification, either in thecourse of acid saponification, or in the course of acidization, after alkaline saponification, produces at least some significant changes in the general character of the blown oil radicals, and thus, We much prefer to use a procedure in which ester formation takes place without going through an acid stage. 5 1

One procedure is to subject such drasticallyblown dehydrated castor oil to methanolysis or ethanolysis. In such particular procedure a glycerol layer is separated and the methyl or ethyl esters obtained with acidification. Such procedure is commonly'employed, particularl in producing'certain polymeric fatty acid esters. For example, see U. S. Patent No. 2,384,443, dated September 11, 1945, to Cowan and Teeter. Briefly then, our preferred procedure involves methanolysis or ethanolysis to produce the methyl or ethyl ester, and then involves the usual reaction so as to volatilize alcohol. This again corresponds to the general description appearing in our aforementioned copending application Serial No. 64,454, filed December 10, 1948.

Our second preferred procedure involves crossesterification with the drastically-blown dehydrated castor oil, with the liberation of glycerol and Without the volatilization of the same. All such procedures for the production of esters are conventional and'require no further description. That will be illustrated, however, by examples.

Example 10 must be made for the polyhydric character ofthe oxyalkylating reactant. In any event, if desired, the hydroxyl value of the oxyalkylated product can be determined b the Verley-Biilsing method, or any other acceptable procedure. The esterification reaction is conducted in any conventional manner, such as that employed for the preparation of the higher fatty acid ester of phenoxyethanol.

Fatty acids, and particularly unsaturated fatty acids, show at least some solubility in the oxyalkylated derivatives of the kind shown in theprevious examples, even though this is not necessarily true of the glycerides of the fatty acids. In this instance, reference is made to the oxyalkylated derivatives in absence of a solvent. Since esterification is best conducted in a homogeneous system, it is our preference to add xylene or even a higher boiling solvent, such as mesitylene, cymene, tetralin, or the like, and conduct esterification in such consolute mixture. It is not necessary to add all the fatty acid at one time. One may add a quarter or half the total amount to be esterified, and aftersuch portion of the reactant has combined, then add more of the fatty acid. The solubility of the fatty acid, of course, increases as the hydroxyl radical is replaced by an ester radical. This is also true if one resorts to trans-esterification or crossesterification with the glyceride or low molal alcohol ester.

Our preference is to have present a substantial amount of xylene or higher boiling, waterinsoluble solvent, and to distill under a reflux condenser arrangement so that water resulting from esterification is volatilized and condensed along with the xylene vapor in a suitably arranged trap. The amount or xylene employed is approxi 

1. AN ESTER IN WHICH THE ACYL RADICAL IS THAT OF THE FATTY ACID OF BLOWN DEHYDRATED CASTOR OIL, AND THE ALCOHOLIC RADICAL IS THAT OF CERTAIN BYDROPHILE POLYHYDRIC SYNTHETIC PRODUCTS; SAID HYDROPHILE SYNTHETIC PRODUCTS BEING OXYALKYLATION PRODUCTS OF (A) AN ALPHA-BETA ALKYLENE OXIDE HAVING NOT MORE THAN 4 CARBON ATOMS AND SELECTED FROM THE CLASS CONSISTING OF ETHYLENE OXIDE, PROPYLENE OXIDE, BUTYLENE OXIDE, GLYCIDE AND METHYLGLYCIDE, AND (B) AN OXYALKYLATION-SUSCEPTIBLE, FUSIBLE, ORGANIC SOLVENT-SOLUBLE, WATERINSOLUBLE PHENOL-ALDEHYDE RESIN, SAID RESIN BEING DERIVED BY REACTION BETWEEN A DIFUNCTIONAL MONOHYDRIC PHENOL AND AN ALDEHYDE HAVING NOT OVER 8 CARBON ATOMS AND HAVING ONE FUNCTIONAL GROUP REACTIVE TOWARD SAID PHENOL; SAID RESIN BEING FORMED IN THE SUBSTANTIAL ABSENCE OF PHENOLS OF FUNCTIONALITY GREATER THAN TWO; SAID PHENOL BEING OF THE FORMULA 